Battery terminal fuse module

ABSTRACT

A fuse module including an battery clamp, a fuse assembly including a mounting block, a bus bar on a first side of the mounting block in contact with the battery clamp, fuse terminals on a second side of the mounting block connected to the bus bar by fusible elements, and a terminal post extending through one of the fuse terminals for facilitating electrical connection to a first electrical component, the fuse module further including a mounting cradle holding the fuse assembly and the battery clamp, the mounting cradle including a mounting post extending through the battery clamp, the bus bar, the mounting block, and one of the fuse terminals for facilitating connection to a second electrical component and for securing the fuse module components together, wherein the mounting post is surrounded by a tubular sleeve extending between the bus bar and the fuse terminal through which the mounting post extends.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/832,477, filed Dec. 5, 2017, which claimed the benefit of U.S.Provisional Patent Application No. 62/430,168, filed Dec. 5, 2016, bothof which applications are incorporated by reference herein in theirentireties.

FIELD OF THE DISCLOSURE

The disclosure relates generally to the field of circuit protectiondevices, and relates more particularly to a battery terminal fuse modulesuitable for automotive battery applications.

BACKGROUND OF THE DISCLOSURE

In the global automotive market there has been a trend towardimplementing so-called “pre-fuse boxes” disposed within automobileengine compartments and connected to automobile battery terminals. Themain purpose of a pre-fuse box in an automobile is to prevent electricaldamage that may result from short-circuiting in high-current-conductingwires that may occur in the event of an accident.

Existing pre-fuse boxes are typically quite large and are mountedadjacent automobile batteries with flexible, conductive leads providingelectrical connections therebetween. This configuration requires a greatdeal of space within an automobile engine compartment where space isalready very limited.

It is with respect to these and other considerations that the presentimprovements may be useful.

SUMMARY

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended asan aid in determining the scope of the claimed subject matter.

A fuse module in accordance with an exemplary embodiment of the presentdisclosure may include an battery clamp, a fuse assembly including amounting block, a bus bar on a first side of the mounting block incontact with the battery clamp, fuse terminals on a second side of themounting block connected to the bus bar by fusible elements, and aterminal post extending through one of the fuse terminals forfacilitating electrical connection to a first electrical component, thefuse module further including a mounting cradle holding the fuseassembly and the battery clamp, the mounting cradle including a mountingpost extending through the battery clamp, the bus bar, the mountingblock, and one of the fuse terminals for facilitating connection to asecond electrical component and for securing the fuse module componentstogether, wherein the mounting post is surrounded by a tubular sleeveextending between the bus bar and the fuse terminal through which themounting post extends.

Another fuse module in accordance with an exemplary embodiment of thepresent disclosure may include an electrically conductive battery clamphaving a ferrule portion adapted for connection to a battery terminaland further having a terminal portion extending from the ferruleportion, a fuse assembly comprising, a mounting block formed of anelectrically insulating material, an electrically conductive bus bardisposed on a first side of the mounting block in contact with theterminal portion of the battery clamp, a plurality of fuse terminalsdisposed on a second side of the mounting block opposite the first sideand connected to the bus bar by respective fusible elements extendingalong a third side of the mounting block, an electrically conductiveterminal post extending through one of the fuse terminals forfacilitating connection to a first electrical component, and anelectrically conductive bus extension mechanically joined to the bus barfor facilitating connection to a fuse, wherein the bus extension differsfrom the bus bar with respect to at least one of material and thickness,the fuse module further including a mounting cradle holding the terminalportion of the battery clamp and the fuse assembly, the mounting cradleincluding a mounting post extending through the terminal portion of thebattery clamp, the bus bar, the mounting block, and one of the fuseterminals for facilitating connection to a second electrical componentand for securing the battery clamp, the fuse assembly, and the mountingcradle together in a stacked arrangement, wherein the mounting post issurrounded by a tubular sleeve that extends between the bus bar and withthe fuse terminal through which the mounting post extends.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view illustrating a fuse module inaccordance with an exemplary embodiment of the present disclosure.

FIG. 2 is an exploded perspective view illustrating a fuse assembly ofthe fuse module shown in FIG. 1;

FIG. 3 is lateral cross-sectional view illustrating the fuse assemblyshown in FIG. 2;

FIG. 4 is longitudinal cross-sectional view illustrating the fuseassembly shown in FIG. 2;

FIG. 5 is perspective view illustrating an alternative embodiment of afuse module in accordance with the present disclosure; and

FIG. 6 is perspective view illustrating another alternative embodimentof a fuse module in accordance with the present disclosure.

DETAILED DESCRIPTION

A battery terminal fuse module in accordance with the present disclosurewill now be described more fully with reference to the accompanyingdrawings, in which preferred embodiments of the battery terminal fusemodule are presented. It will be understood, however, that the batteryterminal fuse module may be embodied in many different forms and shouldnot be construed as being limited to the embodiments set forth herein.Rather, these embodiments are provided so that this disclosure willconvey certain exemplary aspects of the battery terminal fuse module tothose skilled in the art. In the drawings, like numbers refer to likeelements throughout unless otherwise noted.

Referring to FIG. 1, an exploded view of a battery terminal fuse module10 (hereinafter “the fuse module 10”) in accordance with an exemplary,non-limiting embodiment of the present disclosure is shown. As will bedescribed in greater detail below, the fuse module 10 may be coupleddirectly to a positive terminal of an automobile battery with noflexible electrical conductors extending therebetween, and mayfacilitate connection to a plurality of low and medium-current fuses forprotecting a variety of electrical loads (e.g., an air conditioningunit, a stereo, etc.) that are powered by the automobile battery.Advantageously, the fuse module 10 includes an integrated mountingstructure that allows the fuse module 10 to be implemented in a compact,space-saving form factor relative to pre-fuse boxes that are currentlyavailable on the market.

For the sake of convenience and clarity, terms such as “front,” “rear,”“top,” “bottom,” “up,” “down,” “vertical,” and “horizontal” may be usedherein to describe the relative placement and orientation of variouscomponents of the fuse module 10, each with respect to the geometry andorientation of the fuse module 10 as it appears in FIG. 1. Saidterminology will include the words specifically mentioned, derivativesthereof, and words of similar import.

The fuse module 10 may include a battery clamp 12, a fuse assembly 14,and a mounting cradle 16 that may be coupled together in a verticallystacked arrangement as further described below. The battery clamp 12 maybe formed of metal or any other suitably rigid, electrically conductivematerial and may include a ferrule portion 18 (best shown in FIG. 2) forremovably fastening the battery clamp 12 to a positive terminal of anautomobile battery. The battery clamp 12 may further include asubstantially planar, T-shaped terminal portion 20 that extendsgenerally horizontally from the front of the ferrule portion 18. Theterminal portion 20 and the ferrule portion 18 of the battery clamp 12may be formed from a single piece of material (e.g., stamped from asingle sheet of metal) or may be formed from separate pieces of materialthat are welded, clinched, or otherwise joined together in a manner thatprovides robust electrical communication therebetween. It iscontemplated that a ledge, block, or other support structure may beformed on, or affixed to, an underside of the terminal portion 20 tosupport the battery clamp 12 against the weight of the cantilevered fuseassembly 14 and mounting cradle 16 to reduce mechanical stress on theconnection between the ferrule portion 18 and a battery terminal.

Referring now to the exploded view shown in FIG. 2, the fuse assembly 14may include an elongate mounting block 22 formed of an electricallyinsulting material (e.g., ceramic, plastic, polymer, etc.). The fuseassembly 14 may further include a substantially planar bus bar 24 formedof an electrically conductive material (e.g., copper) that extends alonga bottom surface of the mounting block 22. The bus bar 24 may sit atopthe terminal portion 20 of the battery clamp 12 in electricalcommunication therewith. The fuse assembly 14 may further include aplurality of fuses 26 ₁, 26 ₂, 26 ₃ that include respective fuseterminals 28 ₁, 28 ₂, 28 ₃ disposed on a top surface of the mountingblock 22 and connected to the bus bar 24 by respective fusible elements30 ₁, 30 ₂, 30 ₃ disposed on a vertical face of the mounting block 22.The bus bar 24 and the fuses 26 ₁, 26 ₂, 26 ₃ may be formed from asingle piece of conductive material (e.g., stamped from a single sheetof copper) and may be bent or wrapped about the faces of the mountingblock 22. In a non-limiting, exemplary embodiment, the bus bar 24 andthe fuses 26 ₁, 26 ₂, 26 ₃ may be formed of 1-millimeter-thick coppersheet, and each of the fuses 26 ₁, 26 ₂, 26 ₃ may have a rating of 80amps. It will be appreciated that the bus bar 24 and the fuses 26 ₁, 26₂, 26 ₃ are not limited in this regard, and that the bus bar 24 and thefuses 26 ₁, 26 ₂, 26 ₃ may be formed of various other conductivematerials and/or with different thicknesses to achieve different currentratings.

The fuse assembly 14 may further include bus extensions 30, 32 extendingfrom opposing ends of the bus bar 24. Each bus extension 30, 32 may beformed of a segment of sheet metal (e.g., copper sheet) that is bentinto a generally L-shape to define respective, horizontally-orientedbase portions 34, 36 and respective, vertically-oriented extensionterminal portions 38, 40 that extend upwardly alongside the longitudinalend faces of the mounting block 22. The base portions 34, 36 may beclinched, welded, or otherwise joined to the bus bar 24 in a manner thatprovides robust electrical communication therebetween. In anon-limiting, exemplary embodiment, the bus extensions 30, 32 may beformed of 0.8-millimeter-thick copper sheet (i.e., copper sheet that isthinner than the 1-millimeter-thick bus bar 24 described above) tofacilitate connection to fuses having lower amperage ratings (e.g., 5-40amps) than the fuses 26 ₁, 26 ₂, 26 ₃ described above. Theimplementation of such lower amperage fuses via the bus extensions 30,32 will be described in greater detail below.

The fuse assembly 14 may further include electrically conductiveterminal posts 42, 44 having respective polygonal flanges 46, 48extending from their lower ends. The flanges 46, 48 may be seated withinrespective polygonal bores 50, 52 formed in the top of the mountingblock 22 below the fuse terminals 28 ₁, 28 ₃ of the outermost fuses 26₁, 26 ₃, with the terminal posts 42, 44 extending upwardly throughrespective apertures 54, 56 formed in the fuse terminals 28 ₁, 28 ₃ (asshown in FIG. 1). The bores 50, 52 may be of similar size and shape tothe flanges 46, 48 and may be configured to matingly receive the flanges46, 48 in a close-clearance relationship therewith. The flanges 46, 48may thereby restrict rotation of the terminal posts 42, 44 about theirrespective vertical axes. The terminal posts 42, 44 may be threaded forallowing ring terminals of conductors (not shown) to be placed over theterminal posts 42, 44 and secured against the fuse terminals 28 ₁, 28 ₃with nuts (not shown) that may be tightened onto the terminal posts 42,44. Thus, various electrical systems or components of an automobile maybe electrically coupled to a positive terminal of the automobile'sbattery via the terminal posts 42, 44, the fuse terminals 28 ₁, 28 ₃,the fusible elements 30 ₁, 30 ₃, the bus bar 24, and the battery clamp12, with the fuses 26 ₁, 26 ₃ providing over-current protection betweenthe automobile battery and such electrical systems or components.

The mounting cradle 16 may be a generally rectangular, cup-shaped memberformed of an electrically insulating material (e.g., plastic, polymer,etc.). The mounting cradle 16 may hold the terminal portion 20 of thebattery clamp 12 and the bottom of the fuse assembly 14, substantiallycovering the front and sides of the fuse assembly 14, with the terminalportion 20 extending through a recess 57 in the rear of the mountingcradle 16. A threaded mounting post 60 may be rigidly attached to, andmay extend vertically from, a floor 62 of the mounting cradle 16. In anon-limiting example, a flange 59 extending from a lower end of themounting post 60 may be overmolded within the floor 62 of the mountingcradle 16. The mounting post 60 may extend upwardly through an aperture61 in the terminal portion 20 of the battery clamp 12, through anaperture 63 in the bus bar 24, through a bore 64 formed in the mountingblock 22, and through an aperture 65 in the fuse terminal 28 ₂ of thefuse 26 ₂ (see also FIG. 3). Thus, as with the terminal posts 42, 44described above, a ring terminal of a conductor (not shown) may beplaced over the mounting post 60 and secured against the fuse terminal28 ₂ with a nut (not shown) that may be tightened onto the mounting post60. Additionally, tightening a nut onto the mounting post 60 may securethe mounting cradle 16, the battery clamp 12, and the fuse assembly 14together in a vertically stacked arrangement. The mounting post 60 maybe electrically insulated from the bus bar 24, such as by physicalseparation and/or electrically insulating material disposedtherebetween, to prevent electrical current from bypassing the fusibleelement 30 ₂ and flowing from the bus bar 24 to the fuse terminal 28 ₂via the mounting post 60.

Referring now to the cross-sectional view of the module 10 shown in FIG.3, a tubular sleeve 66 may be disposed within the bore 64 in themounting block 22 and may surround the mounting post 60 verticallyintermediate the bus bar 24 and the fuse terminal 28 ₂, with a bottom ofthe sleeve 66 engaging or proximate a top of the bus bar 24 and with atop of the sleeve 66 engaging or proximate a bottom of the fuse terminal28 ₂. In a non-limiting embodiment of the fuse module 10, the sleeve 66may be formed of metal to provide an electrically-conductive pathway(i.e., a shunt) extending directly between the bus bar 24 and the fuseterminal 28 ₂. Such a configuration may be appropriate in applicationswhere it is desirable to bypass the fusible element 30 ₂ and provide anunprotected electrical path from an automobile battery through the fusemodule 10 to electrical systems/components that may be protected byfuses elsewhere in an automobile. In an alternative embodiment of thefuse module 10, the sleeve 66 may be formed of a non-conductive material(e.g., ceramic, plastic, etc.), whereby the only electrically-conductivepath between the bus bar 24 and the fuse terminal 28 ₂ is through thefusible element 30 ₂.

The fuse assembly 14 may further include a cover 70 that may be affixedto a front of the mounting block 22, such as with mechanical fastenersor structures, adhesives, welding, etc. The cover 70 may be disposedover the fusible elements 30 ₁, 30 ₂, 30 ₃ for protecting the fusibleelements 30 ₁, 30 ₂, 30 ₃ from ambient particulate as well as forcontaining electrical arcing in the fusible elements 30 ₁, 30 ₂, 30 ₃that may result from blowing during an overcurrent condition.

Referring now to FIG. 4, the bus extensions 30, 32 may facilitate theconnection of fuses having low-medium amperage ratings (e.g., 5-40 amps)to the fuse assembly 14. For example, the terminal portion 38 of the busextension 30 may have forked terminals 76, 78 (best shown in FIG. 2) forreceiving legs of respective blade fuses 80, 82. The blade fuses 80, 82may be seated within respective recesses formed in the mounting cradle16 and mounting block 22 and may be connected to respective electricalconductors 84, 86 (see also FIG. 1) that extend through apertures in thebottom of the mounting cradle 16.

The top edge of the terminal portion 40 of the bus extension 32 mayfacilitate connection to slotted cartridge fuses 88, 90 which may beseated within respective recesses formed in the mounting cradle 16 andmounting block 22 and may be and connected to respective electricalconductors 92, 94 (see also FIG. 1) that extend through apertures in thebottom of the mounting cradle 16. As described above, the reducedthickness of the bus extension 32 relative to the bus bar 24 allows aconventional slotted cartridge fuse adapted for connection to a 0.8millimeter terminal to be connected to the fuse assembly 14, forexample.

It is contemplated that the mounting cradle 16 of the fuse module 10 maybe provided with numerous features for accommodating various applicationenvironments. For example, referring to FIG. 5, which depicts anembodiment of the fuse module 10 with the bus extensions 30, 32 andaccompanying structures/features omitted, it is contemplated that themounting cradle 16 may be provided with ridges 100, castellations 102,and/or other surface features for routing flexible conductors (notshown) to the terminals posts 42, 44 and to the mounting post 60 in adesired manner. Referring to another example shown in FIG. 6, it iscontemplated that the mounting cradle 16 may be provided with astabilizing arm 104 extending therefrom, the stabilizing arm 104 havingdetents 106, 108 adapted to fit within keyhole-shaped recesses 110, 112in a battery case 115 for preventing rotation of the fuse module 10 andfor providing the fuse module 10 with mechanical strain relief.

It will be appreciated by those of ordinary skill in the art that thefuse module 10 of the present disclosure provides numerous advantagesrelative to pre-fuse boxes that are currently available on the market.For example, owing to the configuration of the above-described mountingcradle 16, with the mounting post 60 extending through, and integralwith, the fuse assembly 14, the entire fuse module 10 can be mounteddirectly to a positive terminal of an automobile battery in closeproximity thereto without any flexible conductors extendingtherebetween. This provides a significant space and material savingsrelative to conventional pre-fuse boxes. Additionally, the busextensions 30, 32, which are mechanically joined directly to the bus bar24, facilitate the provision of terminals with proper mechanical andmaterial characteristics for accommodating low-medium-current fuses incompact configuration.

As used herein, an element or step recited in the singular and proceededwith the word “a” or “an” should be understood as not excluding pluralelements or steps, unless such exclusion is explicitly recited.Furthermore, references to “one embodiment” of the present disclosureare not intended to be interpreted as excluding the existence ofadditional embodiments that also incorporate the recited features.

While the present disclosure makes reference to certain embodiments,numerous modifications, alterations and changes to the describedembodiments are possible without departing from the sphere and scope ofthe present disclosure, as defined in the appended claim(s).Accordingly, it is intended that the present disclosure not be limitedto the described embodiments, but that it has the full scope defined bythe language of the following claims, and equivalents thereof.

The invention claimed is:
 1. A fuse module comprising: an electricallyconductive battery clamp adapted for connection to a battery terminal; afuse assembly comprising: a mounting block formed of an electricallyinsulating material; an electrically conductive bus bar disposed on afirst side of the mounting block in contact with the battery clamp; aplurality of fuse terminals disposed on a second side of the mountingblock opposite the first side and connected to the bus bar by respectivefusible elements; and a mounting cradle holding the fuse assembly and atleast a portion of the battery clamp, the mounting cradle including amounting post extending through the battery clamp, the bus bar, themounting block, and one of the fuse terminals for facilitatingconnection to a second electrical component and for securing the batteryclamp, the fuse assembly, and the mounting cradle together in a stackedarrangement, wherein the mounting post is surrounded by a tubular sleevethat extends between the bus bar and the fuse terminal through which themounting post extends.
 2. The fuse module of claim 1, wherein thetubular sleeve is formed of an electrically conductive material andprovides an electrically conductive path between the bus bar and thefuse terminal through which the mounting post extends.
 3. The fusemodule of claim 1, wherein the tubular sleeve is formed of anelectrically insulating material.
 4. The fuse module of claim 1, furthercomprising an electrically conductive bus extension extending from thebus bar for facilitating connection to a fuse.
 5. The fuse module ofclaim 4, wherein the bus extension is a first bus extension extendingfrom a first end of the bus bar, and wherein the fuse assembly furtherincludes an electrically conductive second bus extension extending froma second end of the bus bar for facilitating connection to another fuse.6. The fuse module of claim 4, wherein the bus extension is forked forreceiving a blade fuse.
 7. The fuse module of claim 4, wherein the busextension defines a flat edge adapted to receive a slotted fuse.
 8. Thefuse module of claim 4, wherein the bus extension differs from the busbar with respect to at least one of material and thickness such that thebus extension has a lower current carrying capacity than the bus bar. 9.The fuse module of claim 1, wherein at least one of the mounting blockand the mounting cradle define a recess for holding a fuse.
 10. The fusemodule of claim 9, wherein adjacent portions the mounting block and themounting cradle together define the recess.
 11. The fuse module of claim1, further including a stabilizing arm extending from the mountingcradle, the stabilizing arm adapted to engage a battery to which thefuse module is connected and to prevent rotation of the fuse modulerelative to the battery.
 12. The fuse module of claim 11, wherein thestabilizing arm includes a protrusion adapted to fit within acomplimentary recess in a battery case.
 13. A fuse module comprising: anelectrically conductive battery clamp having a ferrule portion adaptedfor connection to a battery terminal and further having a terminalportion extending from the ferrule portion; a fuse assembly comprising:a mounting block formed of an electrically insulating material; anelectrically conductive bus bar disposed on a first side of the mountingblock in contact with the terminal portion of the battery clamp; aplurality of fuse terminals disposed on a second side of the mountingblock opposite the first side and connected to the bus bar by respectivefusible elements extending along a third side of the mounting block; andan electrically conductive bus extension mechanically joined to the busbar for facilitating connection to a fuse, wherein the bus extensiondiffers from the bus bar with respect to at least one of material andthickness; and a mounting cradle holding the terminal portion of thebattery clamp and the fuse assembly, the mounting cradle including amounting post extending through the terminal portion of the batteryclamp, the bus bar, the mounting block, and one of the fuse terminalsfor facilitating connection to a second electrical component and forsecuring the battery clamp, the fuse assembly, and the mounting cradletogether in a stacked arrangement, wherein the mounting post issurrounded by a tubular sleeve that extends between the bus bar and withthe fuse terminal through which the mounting post extends.
 14. The fusemodule of claim 13, wherein the tubular sleeve is formed of anelectrically conductive material and provides an electrically conductivepath between the bus bar and the fuse terminal through which themounting post extends.
 15. The fuse module of claim 13, wherein thetubular sleeve is formed of an electrically insulating material.
 16. Thefuse module of claim 13, wherein the bus extension is a first busextension extending from a first end of the bus bar, and wherein thefuse assembly further includes an electrically conductive second busextension extending from a second end of the bus bar for facilitatingconnection to another fuse.
 17. The fuse module of claim 13, wherein thebus extension is forked for receiving a blade fuse.
 18. The fuse moduleof claim 13, wherein the bus extension defines an edge adapted toreceive a slotted fuse.
 19. The fuse module of claim 13, wherein the busextension has a lower current carrying capacity than the bus bar. 20.The fuse module of claim 13, wherein at least one of the mounting blockand the mounting cradle define a recess for holding the fuse.